unlocking hydraulic efficiency with durability · delivering real world efficiency is a valuable...

The Lubrizol Corporation© 2019 The Lubrizol Corporation

Unlocking Hydraulic

Efficiency with Durability

ICIS 2nd Asian Industrial Lubricants

Conference

Nov.13.2019


Hydraulic equipment trends

2

Higher power

density

• High efficiency pumps

• Higher pressures

• Smaller size

Reliability • Digital automation

• Connectivity and smart systems

• Data analytics and condition monitoring

Sustainability• Increased efficiency and productivity

• Reducing emissions and noise

• Hybridization and electrification


Changes in the Hydraulic Equipment Market

Hydraulic fluid performance must meet the needs modern systems demand

Equipment Sophistication

• Higher power densities

• System complexity

• Downsizing

• Running hotter and at higher pressures for longer

3

Fluid Performance Needs

• Increased wear protection

• Wider operating temperature range

• Lower energy consumption

• Need for extended oil life


Hydraulic efficiency and end user needs

Value and definition of efficiency vary by end user

4

Total cost of ownership =

purchase + maintaining + runningThere are no industry standard tests to

measure hydraulic efficiency.

How to describe efficiency?

• Productivity or cycle time

• Energy consumption per unit time

• Work done per amount of fuel

• Temperature reduction

There are many industry standard tests

for hydraulic durability.

Durability

Efficiency


Energy Efficiency in Today’s Market

Delivering real world efficiency is a valuable proposition to industrial end users

• Understanding total system efficiency is critical

‒ Pump efficiency is only one element of hydraulic system efficiency

‒ Energy losses occur in pumps, motors,

hoses, filters, valves and coolers

• Thorough understanding of both hardware and fluid is key to delivering real efficiency

• Total lubricant formulation works together enable real efficiency without compromising

durability.

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Designing Durable Efficient Fluids

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Lubricant performance validation

Bench testing

• Tribology

• Rheology

• Benchmarking

• Candidate screening

• Fundamental

knowledge

Field testing

• Real world proof of

performance

Whole vehicle testing

• Whole system analysis

• Benchmarking

• Final candidate

selection

1 3 4Total system

efficiency rig2

The Lubrizol Corporation7 © 2019 The Lubrizol Corporation

Stage 1

Bench Testing


Bench Testing

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Polymer choice affects fluid traction

• Fluid traction is the internal friction of the squeezed lubricant film

• Low fluid traction contributes to efficiency

• Different viscosity modifiers can affect traction coefficient

VM1 VM2


Stage 2

Lubrizol Total Hydraulic System Efficiency Rig


Hydraulic Efficiency – Pump vs Total System

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Total hydraulic system efficiency

• Volumetric efficiency (ηv)

• Mechanical efficiency (ηm)

• System losses

• Volumetric efficiency

‒ Leakage in different components

o Pump, motor, valve, seal fitting

• Mechanical efficiency

‒ Friction

‒ Pumping

‒ Pressure/ line ΔP

‒ Circuit design

o Excess flow

o Excess pressure

• Overall efficiency is more complex

Hydraulic pump efficiency

• Volumetric efficiency (ηv)

• Mechanical efficiency (ηm)

• Volumetric efficiency

‒ Internal leakage

• Mechanical efficiency

‒ Friction

‒ Pumping

• Overall efficiency

ηo = ηv x ηm

* Green, D. A. World Tribology Congress 2009, Japan, B2-212


Lubrizol Total Hydraulic System Efficiency Rig

• Lubrizol’s laboratory based hydrostatic transmission rig

− Representative of real world mobile equipment

− Uses a hydraulic motor for the working load

− Instrumented to measure efficiency across multiple parts of the hydraulic system

− Flow, temperature, pressure sensors installed around motor, lines, pump, filter, cooler

− Most other studies have focused only on pump efficiency

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Driving

wheelsPump

Motor

Engine


Lubrizol fixed hydraulic efficiency rig

Total hydraulic system efficiency• Small difference in pump efficiency, large difference in motor efficiency

• Total system efficiency shows VM1 to be more efficient

+4%

VM1 VM2


Stage 3

Whole Vehicle Testing


Controlled Whole Vehicle Testing

Measured fuel consumption of two candidates

• Total system field trial

- Extensive instrumentation

- Robust structured testing protocol

- Big data approach – millions of data points

- Statistical analysis

• Quantification of efficiency by duty cycle

- Loaded and unloaded front lifts

- Loaded and unloaded rear lifts

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Proof of performance


Whole Vehicle Testing – Test Method

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Rear boom lift course Front lift laden


Controlled Whole Vehicle Test Results

VM1 offers superior improvements in hydraulic energy efficiency

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VM1 VM2


Stage 4

Field Testing


Field Trial

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Local Excavating Company

• 2015 980M Caterpillar Wheel Loader

• Trial over 3 months

‒ Data logged for 120 hours

Fluids on test

Factory fill: Monograde (Baseline) ISO VG 46

Test Fluid: VM1 ISO VG 46

Shop Oil: Service Fill SAE 10W-30

VM1 VM1


How VM1 improves efficiency?


Measuring Secondary Flow: Data AcquisitionParticle image velocimetry (PIV)

• Tracer particles with sizes (~5-20μm) are added to the fluid

• The light scattered by the particles is recorded at ~ 30,000 frames per second by high

speed camera

• The displacement of the particle images between the successive frames allows the

measurement of the planar 2 dimensional velocity field

Light sheet

Camera

Particles

Test piece

Primary

flow

t t’ velocity

plot

vorticit

y plot

Image processing


Particle Image Velocimetry Data

• Vorticity at the apex of the 180° channel was similarly examined

• For the degree of curvature in the test piece the maximum vorticity was anticipated

at the apex

• Profile at high flow rates becomes increasingly distorted, maximum vorticity

shifting to inner wall

21 VM2 VM1

(1/s)

Apex of 180° bend at 38 L/min-1

Monograde


Particle Image Velocimetry Data

• Quantification of magnitude and area of vorticity can be done for each vertical region

• VM1 fluid was compared to VM2 fluid and shows noticeable differences

• VM1 reduces the magnitude of vorticity by ~10%

• VM1 reduces the area of vorticity by ~18%

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VM1 Vs VM2 VM1 Vs VM2


Summary

VM1 flow characteristics provide energy efficiency to hydraulics

• VM1 substantially reduces secondary flows under hydraulic operating conditions

• Multigrade fluid containing VM2 does not significantly reduce secondary flows

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• These results support all of our hydraulic efficiency testing where VM2 and

monograde fluids appear to perform similarly whilst VM1 containing fluids are

overwhelmingly the most energy efficient

In comparison to monograde fluid

Reduction in

magnitude of

vorticity

Reduction in area of

vorticity

VM 1 11% 20%

VM 2 1% 4%

Lubrizol total hydraulic system efficiency data

+4%

VM1 VM2


Durability Testing


No Compromise on Durability

Efficiency benefits with durability confidence

Strong pump performance ensure fluid durability and equipment protection for a

longer time

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Eaton E-FDGN-TB002-E and Parker Denison HF-0 approved

Fluid formulated with

premium additive and VM1


Bench testing

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Extended shear stability

• Commercially relevant formulations.

• Comparison to shear stable Bosch Rexroth capable VM1 fluid and competitor example.

• VM1 substantially more shear stable out to 200 hours by KRL.

Rupture of coil and orientation Permanent viscosity loss

High shear high load

Fluid formulated with premium additive and VM1

Fluid formulated with premium additive and VM2


Conclusion


Conclusion

• Fluid flow behaviour is a key variable in understanding hydraulic energy

efficiency that does not correlate to viscosity index.

• Careful selection of viscosity modifier can deliver real world efficiency

improvements.

• A balanced hydraulic oil formula can give both durability and efficiency.

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unlocking hydraulic efficiency with durability · delivering real world efficiency is a valuable...

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